First off, I was able to remove the manifold without removing the turbo -- not too difficult to do, just time consuming due to the limited space to with with.

Thanks everybody's help regarding my previous questions regarding removing the manifold.

Now I have the new 3-piece manifold bolted to the engine but my problem is I'm having a heck of a time trying to mate the manifold and the turbo. During the mock up process (just to see if the holes lined up) I had no issues. Please see pics below:





The two studs are in the manifold holes. I'm just unable to make the turbo go up another inch so it will up againts the manifold. I had removed the intercooler tubing from the turbo to create some movement. My next move would've been to loosen the downpipe so I can move the turbo around. I ran out of daylight so I called it quits. Could the oil line be binding things up? I was not sure since there's a flexible hose at the end of it so it can move around.

What bother me also is the wastegate is right up againts the oil filter as it sits right now. I dont remember it being that close. But I think I will be OK once the turbo and manifold are mated. See pics below:




I am completely confused as to why this has become a major pain to put back together. I was able to remove the manifold relatively easy with touching any other components. The turbo and everything remain intact so I'm not sure why I can't move the turbo further up. I'm going to try and loosen the downpipe tomorrow and see if I can creat some movement.

What am I doing wrong here? Pls help.

Anybody with tips and suggestions is greatly appreciated. Thank you.

 

if i remember right the waste gate was on the rear on my turbo......i'll go out in the garage in the morning and take some pic's

 

Yeah, I think you might have to remove the downpipe to free up the turbo. The downpipe and attach points for the exhaust pipe aren't letting the turbo rotate like it should. JM2C....

 

Take the exhaust pipe off of the turbo so you can tip the right side of the turbo in to get past the obstructions then start your bolts and nuts.
Before making them tight get the down pipe hooked up then tighten turbo to manifold and after that the down pipe.

If for some odd reason you are unable to do it this way then remove 1 or both turbo mount studs from the manifold to get the turbo in place by sliding it in.

 

for what it's worth,here's my hx 35/40 hybrid,the wastegate is different than yours

 

Thanks a lot for everybody's help. I finally got the turbo bolted up to the manifold. I removed the downpipe and was then able to move the turbo to the right position. One thing that slowed me down was that I discovered the studs comig off the turbo was now too short for the nut to grab on to the threads since the new manifold flange is almost twice as thick compared to stock. So I had to remove the studs (lots of heat involved to remove it). I went ahead and got grade 10 bolts and a couple of lock washers -- and use those in place of the studs. I'm hoping the clamping force is the same. Another pain point was trying to thread one of the turbo bolts (bottom firewall side) into the manifold. The hex bolt the came with the manifold was too long that the head is right up agains the turbo and as a result I could not stick my allen wrench in the bolt head. So I'm going to get a shorter bolt (regular hex head) so can just use a box end wrench to tighten it. Also lost the nut for the intercooler clamp -- gotta buy that too. So couple more things to do and hopefully I can get this truck running (with no leaks) when I get home from work today. I will get the engine nice and hot and retorque everything.

Thanks for everybodys help. Its been a great learning experience.

 

So the wastegate diaphram is now behind/closer to the engine block in relation to the oil filter?

 

it looks like he has a HY35, the waste gate actuator is on the opposite side of the HX35W

 

Is that a stock manifold?

 

I was just asking because I wanted to know what would be the benefit of changing a stock manifold for another stock manifold?

 

it looks like it's a 3 piece ATS

 

It was looking like the oil filter was interferring with the wastegate diaphram. I just wanted to know where the wastegate diaphram is now.

 

On the turbo where else would you expect it to be

His location is normal looks the same as my 99, it is kind of close to the oil filter but really not that bad once it is in place.

His problem was just while getting it into position and should not be an issue now.

 

So it would be a performance manifold what can you expect to gain with this.